METHOD FOR SPRAYING POLYMERIC COMPOSITIONS WITH COMPRESSED FLUIDS AND ENHANCED ATOMIZATION

Abstract: The present invention is directed to methods for spraying polymeric compositions with supercritical or subcritical compressed fluids such as carbon dioxide or ethane over a wider range of spray conditions to provide improved spray application quality with reduced emission of solvent. The methods are accomplished by using an elongated spray orifice to transform narrow, fishtail, liquid-film sprays to wider, feathered, decompressive sprays.

Description: METHOD FOR SPRAYING POLYMERIC COMPOSITIONS WITH COMPRESSED FLUIDS AND ENHANCED ATOMIZATION FIELD OF THE INVENTION This invention is directed to methods for spraying polymeric compositions using compressed fluids, such as carbon dioxide or ethane, under conditions that enhance atomization. BACKGROUND OF THE INVENTION Many industrial processes spray compositions that contain viscous or solid polymeric components, such as coatings, adhesives, release agents, additives, gel coats, lubricants, and agricultural materials. To spray such materials, it has been common practice to use relatively large amounts of organic solvents. The solvents perform a variety of functions, such as to dissolve the polymers; to reduce viscosity for spraying; to provide a carrier medium for dispersions; and to give proper flow when the composition is sprayed onto a substrate, such as coalescence and leveling to form a smooth coherent coating film. However, the solvents released by the spray operation are a major source of air pollution. Spraying processes have recently been disclosed that reduce organic solvent emissions by using compressed fluids, such as carbon dioxide or ethane, to replace the solvent fraction in solvent-borne compositions. The compressed fluid can reduce the viscosity of the coating composition to facilitate spraying and can assist in atomization of the composition being sprayed. The compositions containing the compressed fluids have been sprayed using essentially conventional airless spray nozzles. Supercritical fluids or subcritical compressed fluids such as carbon dioxide or ethane are not only effective viscosity reducers, but also they can produce a different airless spray atomization mechanism which can produce fine droplet size and a feathered spray. In these processes, compressed fluid is dissolved in the composition. When sprayed, a sudden and large drop in pressure in occurs in the spray orifice, and the compressed fluid is released from solution and expands to produces a force that overwhelms the cohesion, surface tension, and viscosity forces of the liquid mixture to atomize the liquid mixture. Even where compressed fluids are used, often there is a limit to the amount of solvent that can be removed and still provide a sprayable composition, i.e., one that has sufficiently low viscosity that it can be sprayed. A method for spraying liquid compositions containing compressed fluids at higher viscosities, that is at higher solids levels and reduced solvent content, would be particularly advantageous in the effort to reduce solvent emissions. Such method would beneficially increase the range of conditions at which a deco pressive spray is obtained, increase the operating window and reduce the sensitivity of the spray to environmental conditions. SUMMARY OF THE INVENTION By the present invention a method for spraying a liquid mixture of a polymeric composition and at least one compressed fluid which comprises passing the liquid mixture under pressure through a spray orifice that is sufficiently elongated to reduce the average droplet size of the spray. By the methods of the present invention, polymeric compositions can be sprayed with compressed fluids such as carbon dioxide, nitrous oxide, and ethane at a wider range of conditions with enhanced atomization. This allows the polymeric compositions to be sprayed at higher solids levels, with finer atomization, wider spray patterns, and feathered spray patterns, with similar or improved spray application quality and similar or reduced solvent emissions. The operating window for commercial use of the spray process is increased. In accordance with the broader aspects of this invention, the liquid mixture is passed through a first orifice passageway to produce a first spray comprising a liquid-film spray or a transition spray between a liquid-film spray and a decompressive spray, the improvement which comprises providing an elongated first orifice passageway which is elongated in at least an amount such that when spraying the liquid mixture of polymeric composition and at least one compressed fluid through the elongated first orifice passageway, a second spray is produced comprising a decompressive spray or a nearly decompressive spray having smaller average droplet size than the first spray. In a preferred embodiment, the first orifice passageway has a length which is in the range of from about 0.002 inch (0.05 mm) to about 0.020 inch (0.5 mm) and the elongated first orifice passageway has a length which is in the range of "from about 0.020 inch (0.5 mm) to about 0.400 inch (10 mm) . In another preferred embodiment, the polymeric composition is a coating composition. In yet another preferred embodiment, the at least one compressed fluid is selected from carbon dioxide, nitrous oxide, ethane, or a mixture thereof. In still another preferred embodiment, the at least one compressed fluid is a supercritical fluid. Preferably, the average droplet size of the second spray is less than about 70 % of the average droplet size of the first spray, more preferably less than about 50 %. In another embodiment, the liquid mixture of a polymeric composition and at least one compressed fluid is passed through an orifice passageway having a passageway length L and an equivalent diameter D wherein the ratio of L:D is in the range of from about 2:1 to about 20:1, preferably about 3:1 to about 15:1 and more preferably about 4:1 to about 10:1. In still another embodiment, the liquid mixture is passed under pressure through a first orifice passageway to produce a first spray having a spray pattern with a first width that is about the same as or is narrower than the width of the spray pattern produced by passing the polymeric composition under pressure through the first orifice passageway with no compressed fluid and a second spray is produced in the elongated orifice passageway having a spray pattern with a second width that is greater than the first width. Preferably the second spray width is more than about 25% greater, more preferably more than about 50% greater, and still more preferably more than about 100% greater, than that of the first spray pattern. In another embodiment, the liquid coating mixture comprising a coating composition and at least one compressed fluid is passed under pressure through a first orifice passageway to produce a first spray having a fishtail spray pattern and in the elongated passageway a second spray is produced having a feathered spray pattern. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a temperature-compressed fluid concentration diagram at constant pressure illustrating in general terms the conditions at which liquid-film sprays and decompressive sprays are obtained when a liquid mixture of polymeric composition and compressed fluid are sprayed by using a conventional airless spray orifice of the prior art. Figure 2 is a temperature-compressed fluid concentration diagram at constant pressure illustrating in general terms the expanded conditions at which decompressive sprays are obtained by using an elongated airless spray orifice of the present invention. Figure 3a is a rear plan view of a spray orifice body according to the present invention. Figure 3b is a cross-sectional view taken along line 3b-3b of Figure 3a. Figure 4a is a front plan view of another spray orifice body according to the present invention. Figures 4b and 4c are cross-sectional views along lines 4b-4b and 4c-4c, respectively, of Figure 4a. DETAILED DESCRIPTION OF THE INVENTION As used herein, a "compressed fluid" is a fluid which may be in its gaseous state, its liquid state, or a combination thereof, or is a supercritical fluid, depending upon (i) the particular temperature and pressure to which it is subjected, (ii) the vapor pressure of the fluid at that particular temperature, and (iii) the critical temperature and critical pressure of the fluid, but which is in its gaseous state at standard conditions of 0° C and one atmosphere absolute pressure (STP) . A "supercritical fluid" is a fluid that is at a temperature and pressure such that it is at, above, or slightly below its critical point. A "subcritical fluid" is a compressed fluid that is at a temperature and pressure at which it is not a supercritical fluid, whether it be a liquid, a gas, or a gas-liquid mixture. The phrase "polymeric composition" means polymeric compositions, materials, and formulations that have no compressed fluid admixed therewith. "Coating composition", "coating material", and "coating formulation" mean liquid compositions comprising coating compositions, materials, and formulations that have no compressed fluid admixed therewith. The term "solvent" means solvents that have no compressed fluid admixed therewith and which are in the liquid state at conditions of about 25°C and one atmosphere absolute pressure. The phrase "active solvent" means any solvent or mixture of solvents that is miscible with the compressed fluid and is a good solvent for the polymeric compound. The phrase "nonvolatile materials" means solid materials and liquid materials such as solid polymers, liquid polymers, and other compounds that are nonvolatile at a temperature of about 25° C. Compounds which may be used as compressed fluids in the present invention include but are not limited to carbon dioxide, nitrous oxide, ammonia, xenon, ethane, ethylene, propane, propylene, butane, isobutane, chlorotrifluoromethane, monofluoromethane, and mixtures thereof. Preferably, the compressed fluid has appreciable solubility in the polymeric composition. The utility of any of the above-mentioned compressed fluids in the practice of the present invention will depend upon the polymeric composition used, the temperature and pressure of application, and the inertness and stability of the compressed fluid. Due to environmental compatibility, low toxicity, and solubility, carbon dioxide, ethane, nitrous oxide, and mixtures thereof are preferred compressed fluids in the present invention. Due to low cost, non-flammability, stability, and wide availability, carbon dioxide is the most preferred compressed fluid. The polymeric compositions useful in the present invention are generally comprised of a nonvolatile materials portion containing at least one polymeric compound and which is capable of being sprayed. The polymeric compositions, in addition to the nonvolatile materials portion, may also contain a solvent portion which is at least partially miscible with the nonvolatile materials portion. In general, the nonvolatile materials portion is the portion of the polymeric composition that remains after the solvent portion, if any, has evaporated from the polymeric composition. Examples of polymeric compositions that may be used include coating compositions, adhesives, release agents, additive formulations, gel coats, lubricants, non-aqueous detergents, and other compositions containing polymers, which are capable of being sprayed when admixed with compressed fluid. The polymeric compositions that may be used include liquid compositions that are conventionally sprayed using solvents but have reduced or eliminated solvent content. Also included are polymeric compositions which heretofore could not be sprayed, or could not be sprayed well, because the application or product requires that either no solvent or just a low level of solvent be present in the spray, with the maximum permitted solvent level being too low to obtain sufficiently low viscosity to achieve good atomization or to obtain a well-formed spray. Polymeric compositions may comprise at least one polymeric compound which is capable of forming a coating on a substrate, whether such material is a paint, enamel, lacquer, varnish, adhesive, chemical agent, release agent, lubricant, protective oil, non-aqueous detergent, an agricultural coating, or the like. Polymers include thermoplastic polymers, thermosetting polymers, crosslinkable film forming systems, and mixtures thereof. The polymers may be liquid polymers or solid polymers and they may be dissolved in solvent. Examples of polymers are vinyl, acrylic, styrenic, and interpolymers of the base vinyl, acrylic, and styrenic monomers; polyesters; oil-free alkyds, alkyds, and the like; polyurethanes, two-package polyurethanes, oil-modified polyurethanes and thermoplastic urethanes systems; epoxy systems; phenolic systems; cellulosic polymers such as acetate butyrate, acetate propionate, and nitrocellulose; amino polymers such as urea formaldehyde, melamine formaldehyde, and other aminoplast polymers and resins materials; natural gums and resins; silicone polymers such as polydimethylsiloxane and other polymers containing silicon; polymers containing fluorine; rubber-based adhesives including nitrile rubbers which are copolymers of unsaturated nitriles with dienes, styrene-butadiene rubbers, thermoplastic rubbers, neoprene or polychloroprene rubbers, waxes, and the like. The nonvolatile materials portion of the polymeric composition may also comprise other materials such as antioxidants, surfactants, ultraviolet absorbers, whiteners, pigments, pigment extenders, metallic flakes, fillers, drying agents, anti-foaming agents, anti-skinning agents, wetting agents, plasticizers, other chemical agents, polymer additives, abrasives, and glass fibers. A solvent portion may also be employed in the polymeric compositions. The solvent may perform a variety of functions, such as to dissolve the polymer and other components, to reduce viscosity and to give proper flow characteristics, the like. The solvent portion may be essentially any organic solvent or non-aqueous diluent which is at least partially miscible with the nonvolatile materials portion. Preferably, the solvent portion contains at least one active solvent for the polymeric compound. Water may be present, say, up to about 30, preferably up to about 20, % by weight, may also be present in a solvent portion comprising organic solvent, particularly if a coupling solvent is also present. A coupling solvent enables the miscibility of the nonvolatile materials, the solvent, and the water to the extent that a single liquid phase is maintained to facilitate spray and coating quality. The coupling solvent also enables miscibility with the compressed fluid. Coupling solvents include, but are not limited to, ethylene glycol ethers, propylene glycol ethers, and chemical and physical combinations thereof; lactams; cyclic ureas; and the like. Examples of orgainic solvents include ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, methyl amyl ketone, cyclohexanone and other aliphatic ketones; esters such as methyl acetate, ethyl acetate, and other alkyl carboxylic esters; ethers, such as methyl t-butyl ether, dibutyl ether, methyl phenyl ether and other aliphatic or alkyl aromatic ethers; glycol ethers such as ethoxy ethanol, butoxy ethanol, ethoxy 2-propanol, propoxy ethanol, butoxy 2-propanol and other glycol ethers; glycol ether esters such as butoxy ethoxy acetate, ethyl 3-ethoxy propionate and other glycol ether esters; alcohols such as methanol, ethanol, propanol, butanol, amyl alcohol and other aliphatic alcohols; aromatic hydrocarbons such as toluene, xylene, and other aromatics or mixtures of aromatic solvents; aliphatic hydrocarbons such as VM&P (Varnish Makers & Painters) naphtha and mineral spirits, and other aliphatics or mixtures of aliphaticε; and nitroalkanes such as 2-nitropropane. For spraying a polymeric composition which may be a coating composition by the methods of the present invention, the polymeric composition is first admixed with at least one compressed fluid to form a liquid mixture under pressure. The liquid mixture is then sprayed by passing the liquid mixture under pressure through an orifice to form a spray. Compressed fluids have been found to be good viscosity reducing diluents for polymeric compositions such as coating formulations. For example, consider an acrylic coating concentrate that has a viscosity of 1340 centipoise (25° C) . Adding carbon dioxide to 30 weight % concentration reduces the viscosity to below 25 centipoise. Preferably, the viscosity of the liquid mixture of polymeric composition and compressed fluid, when sprayed, is less than about 500, more preferably less than about 200, still more preferably less than about 100, and most preferably less than about 50, centipoise at the temperature of spraying. The viscosity of the liquid mixture is preferably above about 1, more preferably above about 5, and most preferably above about 10, centipoise at the temperature of spraying. Preferably, the compressed fluid has appreciable solubility in the polymeric composition. In general, for the compressed fluid to produce sufficient viscosity reduction and to provide a sufficient expansive force for atomization, the compressed fluid, such as carbon dioxide or ethane, should have a solubility in the polymeric composition of at least about 5, preferably at least about 10, more preferably of at least about 20, and most preferably of at least about 25, weight percent based upon the total weight of compressed fluid and polymeric composition. An orifice is a hole or an opening in a wall or housing, such as in a spray tip of a spray nozzle on a spray gun, through which the liquid mixture of polymeric composition and compressed fluid flows in going from a region of higher pressure, such as inside the spray gun, into a region of lower pressure, such as the air environment outside of the spray gun and around a substrate. The environment into which the liquid mixture is sprayed must be at a pressure sufficiently lower than the spray pressure to enable rapid gasification and expansion of the compressed fluid to occur. Preferably, the polymeric mixture is sprayed into air under conditions at or near atmospheric pressure. Other gaseous environments can also be used. Figure 1 shows how the spray boundaries and the solubility limit of the compressed fluid depend upon the spray temperature and compressed fluid concentration in the liquid spray mixture for constant spray pressure, a given polymeric composition, and a given spray tip. Line 1 in Figure 1 is the solubility limit boundary at constant pressure, which divides the combinations of temperature and compressed fluid concentration that give a single liquid phase (regions A, B, and C) , wherein the compressed fluid is fully dissolved in the polymeric composition, and those that give two fluid phases (region D) , which generally comprise a liquid-liquid mixture or a liquid-gas mixture, depending upon the pressure and the temperature range. In region A of Figure 1, conventional spray widths are obtained with compressed fluids which are typically about the same as or are slightly greater than the width obtained when the polymeric composition is sprayed at the same pressure with no compressed fluid, that is, about the same as the spray width rating of the spray tip. Region B is the transition region in which the spray changes from having a conventional width to having a significantly wider width. Often during the transition, the spray width becomes smaller, sometimes much smaller, before it expands to become significantly wider, often much wider. Spray particle size also decreases. In region C, at higher compressed fluid concentration or higher temperature or both, spray widths are obtained that are significantly larger, often much larger, than those obtained in region A. Wider sprays are also produced in the two-phase region C. These wider sprays are described and shown photographically in U.S. Patent No. 5,009,367. Figure 1 shows how the spray pattern boundaries depend upon the spray temperature and compressed fluid concentration. In region A, fishtail spray patterns are produced because the concentration of compressed fluid is too low, the temperature is too low, or both are too low, to produce a feathered spray pattern. Region B is the relatively narrow range of conditions at which the spray undergoes a transition from a fishtail spray pattern to a feathered spray pattern. In region C, at higher compressed fluid concentration or higher temperature or both, feathered spray patterns are produced. Feathered sprays are also produced in the two-phase region D. Feathered and fishtail sprays are described and shown photographically in U.S. Patent Nos. 5,057,342 and 5,171,613. The compressed fluid concentration necessary to form a decompressive spray with conventional spray orifices is higher with lower polymer levels in the polymeric composition, even though the viscosity may be significantly lower. The decompressive spray boundary (line 2) shifts to higher compressed fluid concentration the same way the solubility limit (line 1) shifts due to higher solubility of the compressed fluid at lower polymer levels. The decompressive spray region is apparently limited to being close to the solubility limit where are used. Typical conventional airless spray orifices have orifice passageways from about 0.002 inch (0.05 mm) to about 0.020 inch (0.5 mm). If the flow time through the spray orifice is too short for nucleation to occur sufficiently, a liquid-film spray occurs and the dissolved compressed fluid rapidly diffuses from the supersaturated liquid film and expands into the surrounding environment, so that very little of the expansive force is utilized for atomization and spray formation. As the nucleation rate increases at higher compressed fluid concentration or higher temperature or both, more nucleation and therefore more gas release occurs within the orifice, so more expansive force is utilized and it becomes more uniformly distributed within the forming spray pattern, which leads to the transformation to a decompressive spray and finer atomization. The elongated orifice passageways of this invention enable a decompressive spray to be obtained at lower compressed fluid concentrations and temperatures where the liquid mixture sprayed contains polymeric composition and compressed fluid. Figure 2 shows how the spray boundaries and the solubility limit of the compressed fluid depend upon the spray temperature and compressed fluid concentration in the liquid spray mixture for the same pressure, the same polymeric composition, and the same compressed fluid used in Figure 1, but with the elongated orifice passageway of the present invention. The solubility limit (line 1) and the two-phase region in Figure 2 are the same as those in Figure 1. Regions B and C and boundary lines 2 and 3 from Figure 1 are shown for reference in Figure 2, with lines 2 and 3 shown dotted. With the elongated orifice passageway of the present invention, as shown in Figure 2, a decompressive spray is obtained not only in region C but in regions B and H as well. A liquid-film spray is obtained in region A as before. A transition spray between a liquid-film spray and a decompressive spray is now obtained in region G, which has spray boundary lines 4 and 5, which are analogous to lines 2 and 3 in Figure 1. The transition region has shifted to lower compressed fluid concentrations and temperatures. With the elongated orifice passageway, a decompressive spray is obtained at the compressed fluid concentrations and temperatures in region B in Figure 2, instead of the transition spray obtained in Figure 1 with a conventional airless spray orifice passageway, at the same concentrations and temperatures. Similarly, with the elongated orifice passageway, a decompressive spray is obtained at the compressed fluid concentrations and temperatures in region H in Figure 2, instead of the liquid-film spray obtained in Figure 1 with a conventional airless spray orifice passageway, at the same concentrations and temperatures. The degree to which the elongated orifice passageway of the present invention shifts the transition region to lower compressed fluid concentrations and temperatures, that is, to what extent a liquid-film spray or a transition spray are transformed into a decompressive spray, will depend upon the length of the elongated orifice passageway, the polymeric composition, the spray pressure, and the compressed fluid used. The elongated orifice passageway of the present invention increases the time available for nucleation to a gaseous compressed fluid phase as it depressurizes in the orifice passageway. A wider spray pattern can also be obtained at lower compressed fluid concentrations and temperatures by using an elongated orifice passageway to spray the liquid mixture of polymeric composition and compressed fluid. This can also be illustrated in general terms by the diagram in Figure 2. With the elongated orifice passageway, as shown in Figure 2, a wider spray is obtained not only in region C but in regions B and H as well. Conventional spray widths are obtained in region A as before. The transition between a conventional spray width and a significantly wider spray width is now obtained in region G, with the transition shifted to lower compressed fluid concentrations and temperatures. The degree to which the elongated orifice passageway of the present invention shifts the transition region to lower compressed fluid concentrations and temperatures, that is, to what extent a conventional spray width or a narrower transition spray width are transformed into a wider spray pattern, will depend upon the length of the elongated orifice passageway, the polymeric composition, the spray pressure, and the compressed fluid used. A feathered spray pattern can also be obtained at lower compressed fluid concentrations and temperatures than are obtained with conventional airless spray orifices by using an elongated orifice passageway. This can also be illustrated in general terms by the diagram in Figure 2. The elongated orifice passageway is elongated in at least an amount such that when the liquid mixture is sprayed through the elongated orifice passageway, a feathered spray pattern is produced, whereas at the same compressed fluid concentration and temperature a fishtail spray pattern is produced by using the conventional airless spray orifice passageway in Figure 1. With the elongated orifice passageway of the present invention, as shown in Figure 2, a feathered spray is obtained not only in region C but in regions B and H as well. Fishtail sprays are obtained in region A as before. The transition between a fishtail spray pattern and a feathered spray pattern is now obtained in region G, with the transition shifted to lower compressed fluid concentrations and temperatures. The degree to which the elongated orifice passageway of the present invention shifts the transition region to lower compressed fluid concentrations and temperatures, that is, to what extent a fishtail spray pattern is transformed into a feathered spray pattern, will depend upon the length of the elongated orifice passageway, the polymeric composition, the spray pressure, and the compressed fluid used. The elongated orifice passageway of the present invention must be sufficiently long relative to the equivalent diameter to effectively produce the decompressive spray, wider spray, or feathered spray, but it must not be so excessively long that an excessive amount of the compressed fluid is converted to a gas while still within the orifice so that the expansive force is severely depleted before the spray is discharged from the orifice. Preferably, the ratio of length to diameter is greater than about 2 and less than about 20, more preferably greater than about 3 and less than about 15, most preferably greater than about 4 and less than about 10. The length of the orifice passageway should desirably be in the range of from about 0.020 inch (0.5 mm) to about 0.400 inch (10mm), and more preferably from about 0.040 inch (1 mm) to about 0.300 inch (7.5mm). The orifice sizes suitable for the practice of the present invention generally range from about 0.004 inch (0.1 mm) to about 0.030 inch (0.75 mm) diameter. Because the orifices are generally not circular in cross-section, the diameters referred to are equivalent to a circular diameter. The proper selection is determined by the orifice size that will supply the desired amount of liquid coating and accomplish proper atomization for the coating. Orifice sizes of from about 0.007 inch (0.18 mm) to about 0.025 inch (0.63 mm) equivalent diameter are preferred, although smaller and larger orifice sizes may be used. Orifice sizes of from about 0.009 inch (0.23 mm) to about 0.020 inch (0.5 mm) equivalent diameter are more preferred. The feed passageway to the inlet of the elongated orifice passageway desirably has a significantly larger cross-sectional area than the orifice passageway, so that the flow resistance in the feed passageway is small compared to the flow resistance in the orifice passageway to prevent a significant loss of pressure before the liquid mixture enters the spray orifice passageway. However, the flow path from the flow control valve, which turns the spray on and off, to the spray orifice passageway desirably has minimal overall volume to promote clean valving of the liquid spray mixture. Although the spray tip body containing the spray orifice may be constructed to produce a round or oval spray pattern, preferably the spray tip body of the spray nozzle assembly contains a groove cut transversely across the outlet of the elongated orifice passageway so as to shape the decompressive spray, wider spray, or feathered spray into a relatively flat spray fan. Preferably the groove is v-shaped or similar shaped such that the angle of the groove regulates the width of the spray fan produced, as is known to those skilled in the art. A spray orifice body 100 that embodies the concepts of the present invention is illustrated in Figures 3a and 3b. Figure 3a shows a rear plan view and Figure 3b shows a cross-sectional view along line 3b-3b in Figure 3a. It has a feed passageway 110 that feeds into a circular elongated orifice passageway 120. A v-shaped groove 130 is cut through the discharge end of the orifice passageway to shape the spray into a relatively flat fan. Orifice passageway 120 has a ratio of length to equivalent diameter of about 5. The spray mixture discharges from orifice passageway 120 as a decompressive spray, a wider spray, or a feathered spray. Another spray orifice body that embodies the concepts of the present invention is illustrated in Figures 4a, 4b, and 4c. Figure 4a shows a front plan view and Figures 4b and 4c show cross- sectional views along lines 4b-4b and 4c-4c, respectively, in Figure 4a. A feed passageway 210 feeds into an elliptical elongated orifice passageway 220. A v-shaped groove 230 is cut through the discharge end of the orifice passageway to shape the spray into a relatively flat fan. Orifice passageway 220 has a ratio of length to equivalent diameter of about 5. The spray mixture discharges from orifice passageway 210 as a decompressive spray, a wider spray, or a feathered spray. It will be readily apparent that the specific curvature or convergence of the sidewalls and edge portions of the feed passageway and the elongated orifice passageway may be modified or altered from that shown to other geometric designs or configurations to produce different specific discharge patterns or to effect different volumetric fluid flow. Likewise, the effective diameters of the feed passageway and orifice passageway and their ratio with respect to each other may be changed without departing from the spirit and scope of the invention. Conventional and electrostatic airless spray nozzle assemblies and spray guns may be assembled with the spray orifice body of the present invention provided they meet the requirements of clean valving and do not interfere with the wide angle at which the decompressive spray leaves the spray orifice. The most preferred spray tip assemblies and spray guns are the UNICARB™ spray tip assemblies and spray guns manufactured by Nordson Corporation for spraying coating compositions with compressed fluids. The material of construction of the spray orifice body must possess the necessary mechanical strength for the high spray pressure, have sufficient abrasion resistance to resist excessive wear from fluid flow, and be inert to chemicals with which it comes into contact. Any of the materials used in the construction of airless spray tips, such as boron carbide, titanium carbide, ceramic, stainless steel or brass, and the like, is suitable, with tungsten carbide generally being preferred for greater wear resistance. Turbulence promoters are not required in the practice of the present invention, but the aforementioned devices and flow designs, such as pre-orifices or turbulence promoters, that promote turbulent or agitated flow in the liquid mixture prior to passing the mixture through the elongated orifice may be used. They preferably do not create an excessively large pressure drop in the flow of the liquid mixture. Pre-orifices can be useful with high molecular weight polymeric compositions, because they pre-shear the composition before it is sprayed, thereby changing the rheology of the liquid mixture. The liquid mixture of polymeric composition and compressed fluid may be prepared for spraying by any of the spray apparatus disclosed in the aforementioned patents or other apparatus. The spray apparatus may also be a UNICARB™ System Supply Unit manufactured by Nordson Corporation to proportion, mix, heat, and pressurize polymeric compositions with compressed fluids such as carbon dioxide for the spray application of coatings. Although high spray pressures of 5000 psi (345 bars) and higher may be used, preferably the spray pressure is below about 3000 psi (207 bars), more preferably below about 2000 psi (138 bars) . Very low pressure is generally not compatible with high compressed fluid solubility in the polymeric composition. Preferably the spray pressure is above about 50, more preferably above about 75, percent of the critical pressure of the compressed fluid, and most preferably above, at, or slightly below the critical pressure. Preferably, the spray temperature of the liquid mixture is below about 150° C, more preferably below about 100° C, and most preferably below about 80° C. The temperature that may be utilized will in general depend upon the stability of the polymeric system. Preferably, the spray temperature of the liquid mixture is above about 20° C, more preferably above about 25° C, and most preferably above, at, or slightly below the critical temperature of the compressed fluid. The liquid mixture is preferably heated to a temperature that substantially compensates for the drop in spray temperature that occurs due to expansion cooling of the decompressing compressed fluid. Generally, liquid spray droplets are produced which generally have an average diameter of one micron or greater. Preferably, the droplets have average diameters of about 5 to about 100 microns, more preferably from about 10 to about 50 microns. While preferred forms of the present invention have been described, it should be apparent to those skilled in the art that methods and apparatus may be employed that are different from those described and shown without departing from the spirit and scope thereof

Claims: WHAT IS CLAIMED IS: 1. In a method for spraying a liquid mixture of a polymeric composition and at least one compressed fluid, which compressed fluid is a gas at 0° C and one atmosphere pressure, which comprises passing the liquid mixture under pressure through a first orifice passageway to produce a first spray comprising a liquid-film spray or a transition spray between a liquid-film spray and a decompressive spray, the improvement which comprises providing an elongated first orifice passageway which is sufficiently elongated that a second spray is produced comprising a decompressive spray or a nearly decompressive spray having smaller average droplet size than the first spray. 2. The method of claim 1, wherein the first orifice passageway has a length which is in the range of from about 0.05 millimeter to about 0.5 millimeter and the elongated first orifice passageway has a length which is in the range of from about 0.5 millimeter to about 10 millimeters. 3. The method of Claim 2, wherein the elongated first orifice passageway has an equivalent diameter in the range of from about 0.18 millimeter to about 0.75 millimeter. 4. The method of Claim 1, wherein the at least one compressed fluid is selected from carbon dioxide, nitrous oxide, ethane, or a mixture thereof. 6. The method of Claim 1, wherein the at least one compressed fluid is a supercritical fluid . 7. The method of Claim 1, wherein the ratio of the elongated first orifice passageway length to its equivalent diameter is in the range of from about 2 to about 20. 8. The method of Claim 1, wherein the average droplet size of the second spray is less than about 70 % of the average droplet size of the first spray. 9. The method of claim 1 wherein the second spray is produced having a spray pattern with a second width that is greater than the first width. 10. The method of claim 1 wherein the second spray has a feathered spray pattern.

Inventors: NIELSEN KENNETH ANDREW, NIELSEN, KENNETH, ANDREW
Applicants: UNION CARBIDE CHEM PLASTIC, UNION CARBIDE CHEMICALS & PLASTICS TECHNOLOGY CORP
Application year: 1994
Main classification: B05D1
IPC codes: B05B1, B05B7, B05D1, B05D7